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Table of Contents
Related Manuals for Yamaha YF200 R1
Summary of Contents for Yamaha YF200 R1
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Page 2: Table Of Contents
Updates, FAQ’s or download the most recent version of the YF200R1 Manual. For more information about the F200 Concept and Rules or to find Resources for your YF200 R1 please visit: www.Speedway-Karting.com Items in Blue are upgrades or XR (Extended Range) products... - Page 3 YAMAHA YF200 R1...
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Page 4: Block & Side Cover
YAMAHA YF200 R1 BLOCK & SIDE COVER Ref # Burris P/N Description F21-101-00 Block / Crankcase with Sleeve F21-102-00 Main Bearing F21-103-00 Seal -Flywheel Side F21-104-00 Oil Drain Plug - 10X16mm F21-105-00 Oil Drain Plug Gasket F21-106-00 Side Cover Dowel Pin -8mm (Solid) -
Page 6: Crank, Piston & Rod
YAMAHA YF200 R1 CRANK, PISTON & ROD Ref # Burris P/N Description F21-200-00 Crankshaft F21-201-01 Billet Rod Assy - Billet w/insert F21-201-02 Bearing Insert For Billet Rod F21-201-03 Rod Bolt & Washer Set F21-202-00 Piston Assy. Std. (71.00mm) F21-202-05 Piston Assy. +.002" (71.05mm) F21-202-10 Piston Assy. -
Page 8: Cylinder Head
YAMAHA YF200 R1 CYLINDER HEAD Ref # Burris P/N Description F21-300-18 R1 Complete Gasket Kit w/.018" HG F21-300-27 R1 Complete Gasket Kit w/.027" HG F21-300-30 R1 Complete Gasket Kit w/.030" HG F21-300-36 R1 Complete Gasket Kit w/.036" HG F21-300-40 R1 Complete Gasket Kit w/.040" HG... -
Page 10: Cam & Valve Train
YAMAHA YF200 R1 CAM & VALVE TRAIN Ref # Burris P/N Description F21-401-00 Camshaft - Unground Lobes F21-401-51 Camshaft - #51 Grind F21-402-00 Intake Valve - 26mm F21-402-20 XR Intake Valve - 26mm Stainless F21-403-00 Exhaust Valve - 24mm F21-403-20... - Page 11 YAMAHA YF200 R1 Page 12...
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Page 12: Carburetor / Manifold
Intake Manifold Complete F21-504-00 Air Filter F21-505-00 Pre- Filter Wrap F21-506-10 Yamaha YF200 R1 Thtottle Linkage Kit F21-507-14 14mm - (.551) Jr. I Restrictor Plate F21-507-16 16mm - (.630) Jr. II Restrictor Plate F21-507-18 18mm - (.709) Jr. III Restrictor Plate... -
Page 14: Flywheel & Ignition
YAMAHA YF200 R1 FLYWHEEL & IGNITION Ref # Burris P/N Description F21-601-00 Fan Housing F21-602-00 Fan Housing Flange Bolt - 6X12mm F21-603-00 T.C.I. Mounting Flange Bolt - 6X20mm F21-604-00 Spark Plug Cap F21-605-00 T.C.I. Unit F21-606-00 Flywheel (offse key) 6° Advance... -
Page 15: Assembly & 6 Packs
ASSEMBLY & 6 PACKS Ref # Burris P/N Description F21-701-00 Exhaust Stud & Flange Nut (kit) (2) 6X15mm Stud, (2) 6mm Flange Nut F21-702-00 Intake Stud & Flange Nut (kit) (2) 6X27mm, (2) 6mm Flange Nut F21-703-00 Cylinder Head Stud & Flange Nut (kit) (2) 8X40mm Stud, (2) 8X55mm Stud, (4) 8mm Flange Nut F21-704-00 Valve Cover Stud (kit) (4) 6X15mm Stud, (4) 6mm Flange Nut, (4) Spacers... -
Page 16: Torque Values
YAMAHA YF200 R1 TORQUE VALUES Item in-lbs ft-lbs m-kg Connecting Rod Bolts* 12.5 17.3 Side Cover Nuts 20.0 27.6 Flywheel Nut 47.0 65.0 Cylinder Head Nuts 18.3 25.3 Rocker Arm Stud Rocker Arm Lock Nut Valve Cover Nuts T.C.I. Flange Bolts... -
Page 17: Special Tools
YAMAHA YF200 R1 SPECIAL TOOLS Page 18... - Page 18 F21-807-00 8mm Stud Installer Side Cover & Head Note: It is strongly recommended you purchase the Com- plete Tool Kit (F21-800-00) when building your YF200 R1 engine. Possible component damage can occur during assembly without the proper tools. Page 19...
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Page 19: Pre-Assembly
Pre-Assembly • Thoroughly clean and inspect parts prior to assembly for damage and compatibility • Crank & Rod Prep: Check the crank journals for any nicks or scratches • and remove them with a fine stone to prevent damage to the bearing seat areas. - Page 20 YAMAHA YF200 R1 • Pre-Assembly • • Seal Installation: The face of the seal should be .290 below the aluminum • boss surface on the block and .200 on the side cover. When installing the seals it is important to apply grease on the O.D. to prevent scuffing or tearing of the seal.
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Page 21: Cylinder Head Prep & Assembly
YAMAHA YF200 R1 Cylinder Head Prep & Assembly • • Cylinder Head Prep: Match and blend intake and exhaust ports with the valve bowls. Pay special attention to the intake runner where it enters the bowl as it is offset to promote swirl and needs to retain the offset in order to maintain the swirl characteristics. -
Page 22: Final Assembly
YAMAHA YF200 R1 Final Assembly • (From here until final assembly use an assembly lube on all sliding and rotating • surfaces except the cylinder wall and rings which require normal crankcase oil.) • • Crankshaft: Slide the crankshaft into the flywheel side bearing. - Page 23 YAMAHA YF200 R1 Final Assembly • • Cylinder Head: Install the • locating dowels and the head gasket over the studs. Put the cylinder head in place and torque in a crisscross manner to 220 in/lbs in 25 in/lbs increments starting at 100 in/ lbs.
- Page 24 YAMAHA YF200 R1 Final Assembly Fuel: We recommend using 89/91 octane pump gas as these engines run well and tune easily with it. Higher octane race gas, besides being illegal, usually requires the timing to be advanced and carburetor to be leaned out to tune properly which in turn makes the engine run hotter and does not show an increase in power over the pump gas.